The Complete Book on Ferrous, Non-Ferrous Metals with Casting and Forging Technology
Author: NIIR Board of Consultants and Engineers Format: Paperback ISBN: 9789381039014 Code: NI148 Pages: 504 Price: Rs. 1,575.00 US$ 150.00 Publisher: NIIR PROJECT CONSULTANCY SERVICES Usually ships within 5 days
The Casting and Forging product is playing a greater role in our everyday lives and is essential than it has ever been. The Casting and Forging industry fortunes is largely dependent on the level of activity within the construction (building and non-building) and automotive sectors. Ferrous and non ferrous metals and its alloys accounts for a large portion of all metal production. Metal ingots and billets are formed by a casting process. The Casting process has traversed a long path and impacted human civilization for nearly five millennia. For any metal casting process, selection of right alloy, size, shape, thickness, tolerance, texture, and weight is very vital. Casting process involves melting the metal to be used, pouring it into a mould, letting it cool and then knocking out the casting. On the other hand, forging is one of the oldest known metal working processes. Forging technology occupies a very important place among all the manufacturing processes as it produces parts with excellent properties and with minimal wastage. Forging involves the use of machinery with a hammering or pressing action to convert basic shapes into a pre-determined form. Forging has the capacity to refine the grain structure and improve the physical properties of the metal. Forging products are consistent, without the defects of porosity, inclusion or voids, and finishing operations like machining, coining, sizing, straightening or surface treatments can also be easily done. This handbook gives a concise description of the fascinating on the state-of-the-art technology of the casting and forging process of metals and metal alloys. This book contains precise details on production of ferrous and non ferrous metals, its casting and forging process along with their alloys. It is hoped that this book will find very helpful to all its readers who are just beginners in this field and will also find useful for existing industries, technocrats, technical institutions, etc.
Contents
CHAPTER 1 Production of Ferrous Metals Production of Pig Iron Blast Furnace Direct Reduction
NIIR Project Consultancy Services (NPCS) 1/10 Furnaces for Steel making and Iron making Basic Oxygen Furnace Electric Furnace Open-Hearth Furnace Cupola Steel Ingots and Strand Casting Refining Furnaces and Vessels Crucible Induction Melting in a Vacuum and Special Atmospheres AOD Process Energy Referred for Melting Ferrous Metals Wrought Iron Steel Carbon Steel Alloy Steel Stainless Steels Cast Iron Effects of chemical elements on cast iron Carbon Silicon Manganese Sulfur Phosphorus
CHAPTER 2 Casting Design, Materials and Economics Introduction Design Considerations Designing for expendable-mold casting Corners, angles, and section thickness Flat areas Shrinkage Parting line Draft Tolerances Machining allowance Residual stress Designing for permanent-mold casting Casting Alloys Nonferrous casting alloys Ferrous casting alloys Economics of casting
CHAPTER 3 Production of Non-Ferrous Metals Properties Non-Ferrous Metals Smelting Furnaces for Non-Ferrous Smelting Production of Aluminium Production of Magnesium
NIIR Project Consultancy Services (NPCS) 2/10 Production of Copper Production of Lead Casting Non-Ferrous Materials Wrought Alloys Aluminium Alloys Copper Alloys Magnesium Alloys Die-Casting Alloys Zinc Base Alloys Aluminium Base Alloys Copper Base Alloys Lead Base Alloys Tin Base Alloys Continuous Casting of Aluminium
CHAPTER 4 Welding and Joining Processes Fundamentals of a Welding System Design fundamental of welded joints ARC Welding Processes Carbon Electrode Welding Metal Electrode Welding Electrode coating Atomic Hydrogen Arc Welding Inert-Gas Shielded-Arc Welding Arc spot Welding Submerged Arc Welding Stud Arc Welding Electroslag Welding Resistance Welding Processes Spot Welding Projection Welding Seam Welding Butt Welding Flash Welding Percussion Welding High-Frequency Resistance Welding Oxyfuel Gas Welding Processes Oxyacetylene Welding Oxyhydrogen Welding Air Acetylene Welding Pressure Gas Welding Solid-State Welding processes Cold Welding Ultrasonic Welding Explosive Welding Diffusion Welding Forge Welding Friction Welding Special Welding Process Induction Welding Electron Beam Welding Laser Welding
NIIR Project Consultancy Services (NPCS) 3/10 Flow Welding Welding Quality and Safety Other Joining Processes Soldering Brazing Adhesive Bonding Allied Processes Oxyacetylene Torch Cutting Transferred-Arc Cuttings
CHAPTER 5 Finish Processes Mechanical Surface Preparation Blast Finishing Process control Chemical Surface Preparation Water Rinsing Dragin Dragout Concentration in the Tank Concentration in the Rinse. Flow Equilibrium and Effectivity Multiple Rinsing Plating Procedure Automatic Control Brush Plasting Metalizing Nonconductors Metalizing Processes Catalytic Deposition Metal Deposition Design Considerations Time and Tank Capacity Determination Thickness Testing Other Metallic Coatings Electroplating Chrome Plating Galvanizing Tin Coating Other Plating Metals Parkerizing Anodizing Calorizing Hard Surfacing
CHAPTER 6 The Crystalline Structure of Metals Space Lattices Lattice Constant Metallic Bond Allotropic Changes Atomic Planes Crystallographic Anisotoropy Cooling Curve
NIIR Project Consultancy Services (NPCS) 4/10 Metallic Dendrite Dendrite Growth Crystal Boundary Grain Shape and Size Astm Grain Size Phases in Metals Intermetallic compounds Solid Solutions Physical Properties of Metals Three Kinds of Stress Engineering Stress and true Stress Engineering Strain and True Strain Engineering Stress strain Diagrams True Stress-strain Diagram Idealized Stress-Strain Diagrams Derivative Types of Stress Ductility Strain Rate Compression Test Tersion Test Combined Deformation Tests Hardness Tests Hardness Versus Strength Hardenability Test Dynamic Impact Test Toughness Heat Resistance Thermal Conductivity Specific Heat Density Thermal Diffusivity Thermal Expansion Thermal Emissivity Corrosion Resistance Electrical Resistivity Magnetic Properties Malleability and Machinability Wear Resistance Classification of Steels and Alloys Major Classifications and Specifications Unified Numbering System AISI-SAE Designation System Carbon Steels Alloy Steels Tools Steels Stainless Steels Electrical Sheet Steels Heat Resisting Alloys
CHAPTER 7 Conditioning Semi-Finished Products Introduction Ingot Defects
NIIR Project Consultancy Services (NPCS) 5/10 Surface Defects Originating in Soaking Pits Defects Resulting From Hot-Rolling Practices The Classification of Surface Defects for Conditioning Method of Surface-Defect Detection The Mechanical Removal of Surface Defects Conditioning by Scarfing
CHAPTER 8 Structural Mills Introduction The Evaluation of Structural Mills Universal Beam Mills Modern Structural Mills for Rolling Large Beams Modern Mills for Medium Sections
CHAPTER 9 The Reheating of Ingots Introduction The General Layout and Design of Soaking-Pit Facilities Gaseous Fuels and Burners used in Soaking Pits The Use of Oil for Heating Soaking Pits Heat Recovery in Soaking -Pit Operations Two-Way Fired Soaking Pits One Way Fired Soaking Pits Bottom Center-Fiord of Vertically Fired Pits Circular Pits Electric Soaking Pits Pit Covers and Seals Automatic Controls for Soaking Pits Handling the Ingots by Crane Tongs
CHAPTER 10 Forging Introduction Open-Die Forging Cogging Precision Forging Forging Force Coining Related Forging Operations Heading Piercing Other Operations Rotary Swaging Forging-Die Design Die Material and Lubrication Forgeability Forging Machines Presses Mechanical Presses Screw Presses Hammers Counterblow Hammers
NIIR Project Consultancy Services (NPCS) 6/10 High-Energy-Rate Machines Selection of Forging Machines Forging Practice and Process Capabilities Automation in Forging Economics of Forging
CHAPTER 11 Metal Casting processes Introduction Sand Casting Types of Sand Molds Patterns Cores Sand Molding Machines Sand Costing operation Shell Mold Casting Composite molds Sodium silicate process Rammed graphite molding Expandable pattern casting (lost Foam) Plaster Mold casting Ceramic Mold Casting Investment Casting Vacuum Casting Permanent Mold Casting Slush Casting Pressure Casting Die Casting Hot Chamber process Cold chamber process Process capabilities and machines selection Centrifugal Casting Squeeze Casting and Semisolid Metal Forming Squeeze casting Semisolid metal forming Casting Technique for Single Crystal component Rapid solidification (Amorphous alloys) Inspection of castings Melting practice and furnaces
CHAPTER 12 Foundry Processes Sand casting and Molding procedures Green Sand Mold Loam Nold Furfuryl Alcohol Binder Molds CO2 Molds Skin Dried Molds Dry Sand Molds Metals and Special Molds Goting System and Solidification Characteristics Patterns Allowances
NIIR Project Consultancy Services (NPCS) 7/10 Removable patterns Sand Technology Mold and Core Hardness Test Fineness Test for moisture Content Clay content Test Permeability Test Sand conditioning Cores Green Sand Cores Dry sand Cores Core Making Binders and Core Mixtures Molding Equipment Jolt Machine Squeezer Machine Jolt Squeeze Machine Sandslinger Diaphragm Molding Machine Pouring and cleaning castings
CHAPTER 13 Tube Mills Introduction Typical Skelp Mill The production of continuous butt-welded pipe The production of electric-resistance-welded tubing and electric-welded large-diameter pipe The production of seamless shells or Bottles by Direct Punching Rotary Piercing machines Rotary Rolling Mills The Plug Rolling Mill Reeling The Mandrel Mill Sizing and Stretch Mills The Pilger Mill Other Type of Mills Used in The Production Of Tubes The Diescher Mill Modern Seamless Tube-Making Facilities
CHAPTER 14 The cooling of Mill Rolls Introduction Heat Conduction equations Solution toTtransient Heat Conduction Problems Mathematical Models Pertaining to Transient Heat Flow in Work Rolls Measured One-Dimensional Temperature Patterns in Mill Rolls Predicating the Roll Surface Temperature Rise in The Roll Gap The Water Cooling of Rrolls and Measurement of Heat Transfer Coefficients Sprays and Their Pplacement for Optimum Roll Cooling
CHAPTER 15 Extrusion and Drawing Introduction
NIIR Project Consultancy Services (NPCS) 8/10 Extrusion Force Metal Flow in Extrusion Extrusion Practice Hot Extrusion Die Design and Materials Lubrication Cold Extrusion Impact Extrusion Extrusion Defects Surface cracking Pipe Internal Cracking Extrusion Equipment The Drawing Process Drawing Practice Die design Die Materials Lubrication Defects and Residual Stresses Drawing Equipment
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